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Check out the following for the nuvi's pinouts & wiring to verify:
Re: the battery, I'm not 100% certain how the non-removable battery units will react with a bad battery but in my experience, it *should* power on normally, even if the battery is bad.
If could be that having the flaky mini-USB connector could have cause file corruption at some point if you've had it connected to the PC and did any file manipulation. The USB connector on many of these Garmin models (the USB connector is mounted at a 90 degree angle to the PCB) is cause for alot of issues. Having a corrupted file system could cause the unit to fail to boot.
See: http://www.sharc.net/gps_charger_repair.htm and scroll down to "Loose/Broken Mini-USB Port" for more info that may be useful to you.